Technical Service Bulletin: 2001-03 Elantra Corrosion in The Front Door Wiring Connector

Technical Service Group
BODY ELECTRICAL
Bulletin Number
06-90-008
Subject Date
FEBRUARY, 2006
2001-03 ELANTRA CORROSION IN THE
FRONT DOOR WIRING CONNECTOR Model
2001-2003 ELANTRA
This bulletin supersedes TSB# 03-90-009 to update the sealant information.

DESCRIPTION:
A water leak between the front outer panel and cowl panels may result in corrosion of
the front door wiring connector pins if the vehicle is operated in areas where road salt is
used. The corrosion may affect the operation of the electrical circuits in the door, such
as the speakers, power windows, etc.
To correct this condition, reseal the seams and inspect the door wiring connectors for
corrosion. If necessary, replace the door wiring connector and the door wiring by
following the service procedures described in this TSB.
Page 1 of 24
PARTS REQUIRED:
Detailed List of Parts Included in the Kit:
MODEL KIT NAME KIT PART NUMBER PART NAME QTY
Wiring Assy (1) 1
Floor Harness -
Driver’s side door 91500-2DC00 Vinyl Sheet (2) 2
ELANTRA wiring connector kit assembly (C)
Heat Shrink Tube (3) 26
produced before
October 20, 2000 Wiring Assy (1) 1
Floor Harness -
Passenger’s side door 91500-2DD00 Vinyl Sheet (2) 2
wiring connector kit assembly (D)
Wiring Assy (1) 1
Floor Harness -
Driver’s side door 91500-2DA00 Vinyl Sheet (2) 2
ELANTRA wiring connector kit assembly (A)
produced after
November 2, 2000 Wiring Assy (1) 1
Floor Harness -
Passenger’s side door 91500-2DB00 Vinyl Sheet (2) 2
wiring connector kit assembly (B)
NOTE: For vehicles produced between October 20, 2000 and November 2, 2000, the wire harness wire colors were
mixed based on vehicle options. Check the wire colors on Pin #2 (Driver Side - MD01) and Pin #8 (Passenger Side -
MD03) on each side to determine which kits will be color matched to the vehicle being repaired. (See Connector Kit
Identification section below).
The difference between the two LH kits is the wire colors; so they can be interchanged if necessary, by splicing the
wires by pin location, not color. The same applies to the RH kits.
KIT CONTENT: ID TAPE COLOR

1 A: BLACK
1. Wiring Assy. B: BLUE
C: YELLOW
D: RED
2. Vinyl Sheet 3
3. Heat Shrink Tube

2
CONNECTOR KIT IDENTIFICATION:

<CONNECTOR VIEW (MD01/MD03) -
ID TAPE COLOR BLACK (A) BLUE (B) YELLOW (C) RED (D)
FLOOR HARNESS SIDE (FEMALE)>
Page 2 of 24
BODY ELECTRICAL
Bulletin Number
06-90-008
CONNECTOR KIT IDENTIFICATION:

Connector P/N (91500- )
Wire color 2DA00 2DB00 2DC00 2DD00
Pin #2 (MD01) Gray - Brown -
Pin #8 (MD03) - Gray - Brown
PARTS REQUIRED (CONTINUED):

PART NAME PART NUMBER FIGURE
3M Flexiclear Body Seam

Sealer (PN-051135-08405) or
Source Locally
equivalent and cartridge
applicator
Undercoating: 3M underseal
rubberized under-coating Source locally
(PN-08883) or equivalent
Contact Cleaner Source Locally
Connector Grease 00305-F0000-39
Page 3 of 24
SERVICE PROCEDURE:
Page 4 of 24
BODY ELECTRICAL
Bulletin Number 06-90-008
SEALING THE PANEL SEAMS:

NOTE: This sealing procedure applies to both left and right sides.
1. Open the hood.
2. Locate the “A” pillar outer panel and cowl panel seaming area at the base
of the “A” pillar.
HOOD PANEL HOOD PANEL
RIGHT FENDER PANEL LEFT FENDER PANEL
3. Lift up the lower end of windshield glass

molding to obtain space for sealant
application.
LEFT
FENDER
PANEL
WINDSHIELD GLASS
MOLDING
4. Clean the sealant application area on both “A” PILLAR

the left and right sides of the vehicle FENDER
(fender removed in photo for clarity). MOUNTING
BRACKET
DOOR
CLEAN HINGE
THE SEALANT
APPLICATION
AREA COWL
Page 5 of 24
5. Apply clear sealant along the seam line
SEALANT
between “A” pillar panel and cowl panel TUBE
from the engine compartment as shown
in the photo.
6. Use appropriate tool or finger (with rubber
nitrate gloves) to smooth material to seal
the sealant.
NOTE: Apply enough sealant to “A” PILLAR

completely fill the seam.
FENDER
F
Be careful not to drip excess MOUNTING
sealant in the engine compartment BRACKET
or on the hood.
- Photo shows panel seams where

sealant is applied on left side. SEALANT
DOOR
APPLICATION HINGE
AREA COWL
- Repeat for the right side.
7. Open the front door.
8. Apply the clear sealant to the seam
between “A” pillar panel and the fender “A” PILLAR
mounting bracket from inside the door
opening. SEALANT
TUBE
9. Apply the clear sealant to the bottom of FENDER
the fender mounting bracket and the top MOUNTING
of the hinge. BOLT
10. Use appropriate tool or finger (with

rubber nitrate gloves) to smooth material
to seal the sealant.
NOTE: Apply enough sealant to FENDER
completely fill the seam. Be MOUNTING
BRACKET
careful not to drip excess sealant
on the door trim or in the interior.
- Sealant is applied along the top “A” PILLAR

edge of the fender bracket.
SEALANT
APPLICATION
AREA
Page 6 of 24
BODY ELECTRICAL
Bulletin Number
06-90-008
- Sealant is applied along the bottom

of the fender mounting bracket and
the top of the hinge.
APPLY
SEALANT
TO THE
BOTTOM
APPLY OF THE
SEALANT FENDER-
TO TOP OF MOUNTING
HINGE BRACKET
DRIVER’S SIDE DOOR WIRING CONNECTOR INSPECTION:

1. Turn on the ignition key and lower the door
glass. Record the customer’s radio
stations. Turn the ignition off and then
remove the negative battery cable.
NOTE: The following procedure requires
two people to perform part of the
operations.
2. Open the driver’s side front door. Position
FRONT DOOR
a floor jack under the middle of the door.
Cover the top of the jack with padding.
Raise the jack just enough to partially
support the door.
JACK
3. Remove the front door checker mounting

bolt (1EA) from the front door and remove
the upper and lower door hinge mounting
bolts (4EA). Balance the door on the jack.
NOTE: Be careful not to scratch or
damage the door. Be sure to
support the door so it does not fall
during removal.
Page 7 of 24
- The top hinge bolts.
- The bottom hinge bolts are similar.
4. Have a helper support the door. Use a

GROMMET
pair of needle nose pliers to gently pull
the rubber grommet off of the connector.
NEEDLE
NOSE
PLIERS
5. Release the 4 connector locking clips by

pressing them one at a time, working
around the connector. 2 1
4
6. Disconnect the connectors.
MD01
GROMMET
MD02
Page 8 of 24
BODY ELECTRICAL
7. Remove the front door assembly. Set it on

a clean soft cloth where it will not be
scratched or damaged.
NOTES:
• Be careful not to scratch or damage
the door panel, fender panel or
rocker panel when removing the
front door assembly.
• Carefully store the removed door
panel where it will not be scratched
or damaged.
8. Check the removed connectors for
corrosion and dirt.
MD02
MD01
9. If the connectors are not corroded or are CONNECTOR

just slightly corroded, use an electrical GREASE
contact cleaner to flush the connectors
until they are clean. Flush the door side
of the connector clean as well.
Inject connector grease into each

opening of the female connector terminal
on the floor wire harness side.
________________________________
Recommended Grease:
GREASE - NYOGEL 760G
P/N 00305-F0000-39
________________________________
Page 9 of 24
NOTE: If the connector terminals have
more than light corrosion, they
cannot be cleaned, they must be
replaced.
Proceed with driver’s side door

wiring connector and door wiring
replacement procedure as
explained in the “Driver’s Side
Door Wiring Connector and Door
Wiring Replacement” section on
page 14 of this TSB.
10. Fit the grommet over the flange on the SEALANT
door wire harness connector. Apply a INJECTOR
small amount of the clear sealant around
the edges of the grommet as shown in
the photo.
11. Place the removed front door assembly

back on the jack, lined up with the GROMMET
hinges. Have a helper support the door.
12. Connect the door connector to the
vehicle connectors. Carefully install the
door wire connector back into the
mounting hole. Be careful to keep the
grommet in position.
NOTE: If the grommet separates from the
connector, remove the connector,
refit the grommet in position,
reapply a small amount of sealant
to the grommet and reinstall the
connector. The grommet must
make a water tight seal to the
body.
13. Install the front door assembly and install
the front door checker.
NOTE: Check the door opening and
closing effort and the door
alignment to the body. Adjust the
door if necessary.
14. Close the door.
Page 10 of 24
BODY ELECTRICAL
Bulletin Number
06-90-008
PASSENGER’S SIDE DOOR WIRING CONNECTOR INSPECTION:

1. Open the passenger’s side door.
2. Remove the door sill trim.
3. Remove the right cowl side trim.
COWL SIDE
TRIM
4. Unclip the main wire harness from the

CONNECTOR
connector cover. Cut the wire tie holding COVER
the MD03/MD04 connector wires to the
connector cover. Remove the wiring CLIP COVERING
connector cover mounting bolts (2EA) and BOLT
then remove the cover.
5. Follow the MD03/MD04 connector wires BOLT
W TIE
WW
WIRE
up to the connectors, disconnect the (MD03/MD04
connectors. The release for the top CONNECTOR WIRES)
connector is on top, the release for the
bottom connector is on bottom.
6. Release the 4 door wiring harness
connector locking clips by pressing them
one at a time, working around the
connector. Push the connector out of the
body hole.
DOOR
CONNECTOR
Page 11 of 24
7. Inspect the removed connectors for REMOVED MD03/MD04
corrosion and dirt. CONNECTORS
8. If connectors are not corroded or are just CONDUCTIVE

GREASE
slightly corroded, use an electrical contact MD03
cleaner to flush the connectors until they
are clean. Flush the door side of the
connector clean as well.
WARNING: Protect the inside of the
vehicle so the contact
cleaner will not splash onto
the trim.
9. Inject connector grease into each opening
of the female connector terminal on the
floor wire harness side.
________________________________
Recommended Grease:
GREASE - NYOGEL 760G
P/N 00305-F0000-39
________________________________
NOTE: If the connector terminals have

more than light corrosion, they
cannot be cleaned, they must be
replaced.
Proceed with passenger’s side

door wiring connector and door
wiring replacement procedure as
explained in the “Passenger’s
Side Door Wiring Connector and
Door Wiring Replacement”
section on page 21 of this TSB.
Page 12 of 24
BODY ELECTRICAL
10. Fit the grommet over the flange on the SEALANT

door wire harness connector. Apply a INJECTOR
small amount of the clear sealant around
the edges of the grommet as shown in the
photo.
GROMMET
11. Carefully install the door wire connector PASSENGER’S SIDE

back into the mounting hole. Be careful to
keep the grommet in position.
NOTE: If the grommet separates from the GROMMET

to the grommet, and reinstall the
connector.
12. Reconnect the door wiring connector. CONNECTOR
COVER
13. Install the wiring connector cover.
14. Re-clip the main wire harness in the CLIP COVERING
connector cover slip. BOLT
15. Use a wire tie to secure the door BOLT

connector wires to the connector cover.
WIRE TIE
(DOOR CONNECTOR)
16. Install the right cowl side trim.

17. Install the door sill trim.
18. Connect the negative battery cable and COWL SIDE
reset the customer’s radio stations. TRIM
19. Close the hood.
Page 13 of 24
DRIVER’S SIDE DOOR WIRING CONNECTOR AND DOOR WIRING
REPLACEMENT:
NOTE: This procedure applies to an excessively corroded driver’s side door
wiring connector. Steps 1 - 8 involve replacing the connectors on the
floor wire harness, and steps 9 - 19 involve replacing the door wire
harness.
1. Cut and remove the first 2.5 - 3 inches “A” PILLAR
(about 70 mm) of the vinyl sheathing from
the door wiring. Be careful not to nick the
wires.
70 mm
2. Take the most corroded wire in the

connector first. Cut it about 1 inch “A” PILLAR
(25mm) from the connector. If it is
corroded at the cut, cut an additional 1
inch. If the wire is black, it is OK. Strip
the wire end about 0.25 inch (7mm).
NOTES:
• Only cut and solder one wire at a
time to avoid confusing the same
color wires in each connector. If
you have the wrong driver’s side
door wiring connector kit, you will
be able to match the wires by pin
location, even though the colors will
not exactly match.
• Pin 17 of MD02 connector will have a
smaller gauge yellow wire if the
vehicle has the factory keyless
entry option. Connect it to the
larger red wire supplied on the
connector.
Page 14 of 24
BODY ELECTRICAL
• If the wires are corroded more than 2

inches from the connector, you may
need to access them from inside the
vehicle. The procedure for
removing the cowl trim and
connector cover is similar to the
passenger side inspection
procedure noted on page 11 of this
TSB.
3. Strip the corresponding wire from the
replacement connector (0.25inch, 7mm).
Be sure to verify the wire position in the
new connector matches the position the
wire was cut from in the original
connector.
4. Slide a piece of the heat shrink tube onto

the wire. Interlace the two stripped wires.
HEAT SHRINK
TUBE
5. Solder the wires.

WARNING: Do not allow the solder to drip
on the vehicle paint or trim.
Protect the area as necessary.
Page 15 of 24
6. Slide the heat shrink tube over the
soldered joint and exposed wire; apply
HEAT SHRINK
heat to the tube until it shrinks, covering TUBE
the wire completely. Heat shrink tubing
should extend 0.5 inch (13 mm) past the
exposed wire on both ends of the joint.
NOTE: Apply steps 2) through 6) to the
other wires in both connectors.
7. Some wires on the new door connector kit

may not be used (different options). In
this case, cut the unused wires 1 inch
TAPING
(25mm) from the connector and tape the
cut ends.
8. Wrap the spliced wire harnesses with the

VINYL SHEET
supplied vinyl sheet.
Page 16 of 24
BODY ELECTRICAL
9. Remove the front door quadrant inner

cover from inside the mirror mounting
area. QUADRANT
INNER
COVER
10. Remove the door trim mounting screws

and door inside handle housing from the
front door assembly. Pop the trim clips
loose along the bottom edge of the door.
Remove the power window switch
connector and related connectors and
remove the door trim panel assembly.
11. Remove the door trim seal.

NOTE: The door trim seal must be
replaced if it is torn or damaged.
Any leaks may cause door trim
panel damage, or water leakage
into the vehicle interior.
DOOR TRIM SEAL
12. Disconnect the door speaker connector

DOOR
and then remove the door speaker. SPEAKER
CONNECTOR
Page 17 of 24
13. Remove the front door wiring.
DOOR
WIRING
14. Replace the door wiring with a new

part.
IMPORTANT: Verify you have the
correct new door wiring
assembly part number.
Refer to page 19 of this
TSB.
Page 18 of 24
BODY ELECTRICAL
Bulletin Number
06-90-008
DOOR WIRING ASSEMBLY PART NUMBER INFORMATION:
PRODUCTION DATE RANGE PART DESCRIPTION PART NUMBER

Elantra produced
Driver’s Side Door Harness
7/01/00 - 4/23/01 91600-2D010
WITH keyless entry
(4DR & 5DR GLS)
Elantra produced
7/01/00 - 4/23/01 91600-2D030
WITHOUT keyless entry
(4DR & 5DR GLS)
Elantra produced
7/01/00 - 4/23/01 91600-2D040
(4 DR GL)
Elantra produced
4/23/01 - 3/13/02 91600-2D011
WITH keyless entry
(4DR & 5DR GLS)
Elantra produced
4/23/01 - 3/13/02 91600-2D041
(4DR GL)
Elantra produced
3/13/02 - 91600-2D042
(4DR GL)
Elantra produced
3/13/02 - 91600-2D012
WITH keyless entry
(4DR & 5DR GLS)
Elantra produced
3/13/02 - 91600-2D032
(4DR & 5DR GLS)
Elantra produced Driver’s Side Door Harness
7/18/02 - WITHOUT keyless entry and 91600-2D052
(4DR & 5DR GL) heated mirror
Elantra produced Driver’s Side Door Harness
7/18/02 - 10/10/02 WITHOUT keyless entry and 91600-2D280
(5DR GL) door courtesy lamp
15. Install the front door speaker.

16. Install the front door trim seal.
17. Install the front door trim panel.
18. Install the front door quadrant inner cover.
Page 19 of 24
19. Apply a small amount of the clear sealant SEALANT
around the edges of the grommet as INJECTOR
shown in the photo.
GROMMET
20. Place the removed front door assembly

back on the jack, lined up with the hinges.
Have a helper support the door.
21. Connect the door connectors to the DRIVER’S SIDE
vehicle connectors. Carefully install the
door wire connector back into the
mounting hole. Be careful to keep the GROMMET
grommet in position.
NOTE: If the grommet separates from the
to the grommet, and reinstall the
connector. The grommet must
make a water tight seal to the
body.
22. Install the front door assembly and install
the front door checker.
NOTE: Check the door opening and
closing efforts and the door
alignment to the body. Adjust the
door if necessary.
23. Close the door.
Page 20 of 24
BODY ELECTRICAL
Bulletin Number
06-90-008
PASSENGER’S SIDE DOOR WIRING CONNECTOR AND DOOR WIRING

REPLACEMENT:
NOTE: This procedure applies to an excessively corroded passenger’s side door
wiring connector. This section will refer to the individual steps that have
been covered in earlier sections.
1. Lay down a protective covering over the passenger side carpeting. Perform the
same steps to solder the wiring connector kit to the vehicle wire as performed in
steps 1 through 8 in the “Driver’s Side Door Wiring Connector and Door Wiring
Replacement” section.
2. Replace the passenger front door wire harness. Follow the procedure in steps 9
through 18 in the “Driver’s Side Door Wiring Connector and Door Wiring
Replacement” section. Use the following part numbers to select the correct
passenger front door wire harness.

Elantra produced
Passenger’s Side Door Harness
7/01/00 - 4/23/01 91620-2D010
WITH keyless entry
(4DR & 5DR GLS)
Elantra produced
7/01/00 - 4/23/01 91620-2D030
(4DR GLS)
Elantra produced
7/01/00 - 4/23/01 91620-2D040
(4DR & 5DR GLS)
Elantra produced
4/23/01 - 3/13/02 91620-2D011
WITH keyless entry
(4DR & 5DR GLS)
Elantra produced
4/23/01 - 3/13/02 91620-2D031
(4DR GL)
Elantra produced
4/23/01 - 3/13/02 91620-2D041
(4DR & 5DR GLS)
Elantra produced Passenger’s Side Door Harness
3/13/02 - WITHOUT keyless entry - 91620-2D032
(4DR GL) no manual central door locking
Elantra produced
3/13/02 - 91620-2D012
WITH keyless entry
(4DR & 5DR GLS)
Page 21 of 24
Elantra produced
3/13/02 - 91620-2D042
(4DR & 5DR GL & GLS)
Elantra produced
7/18/02 - 91620-2D042
(4DR & 5DR GL)
7/18/02 - WITHOUT keyless entry and 91620-2D062
(4DR GL) heated mirror
7/18/02 - 10/10/02 WITHOUT keyless entry and 91620-2D250
(5DR GL) door courtesy lamp
3. Insert the door wire harness connector back into the body hole. Follow the
procedure in steps 19 and 21 in the “Driver’s Side Door Wiring Connector and Door
Wiring Replacement” section (Page 20).
4. Connect the connectors.
5. Finish the repair by following steps 12 through 19 in the “Passenger’s Side Door
Wiring Connector Inspection” section on page 13 to reassemble the vehicle.
Page 22 of 24
BODY ELECTRICAL
Bulletin Number
06-90-008
INNER FENDER PANEL SEAM SEALING:

NOTE: This procedure applies to both left and right sides.
1. Lift up the vehicle.
2. Remove the front wheel and tire.
3. Remove the plastic front wheel guard

(splash trim).
4. Spray all panel seams through the access

hole inside the fender panel with 3M
UNDERSEAL (3M PN-08883)
undercoating or equivalent as shown in SPRAY
the photo.
continued
Page 23 of 24
4) continued:
BEFORE SPRAYING
Spray all panel seams with undercoating. ACCESS

HOLE
AFTER SPRAYING
UNDERCOATING
5. Reinstall the front wheel guard and tire.

6. Repeat for the opposite side.
7. Lower the vehicle and close the hood.
WARRANTY INFORMATION:
OP OP CAUSAL NATURE CAUSE
OP CODE OPERATION
TIME QTY PART NUMBER CODE CODE
Body sealing and corrosion protection,
91500R0F 1.2
door wiring inspection (both sides)
91501R0F door wiring inspection (both sides) and 3.5
replacement (one side only)
1 71110-2DA10 *N56 **C88

91502R0F door wiring inspection (both sides) and 4.6
replacement (both sides)
*N56: Rust, Corrosion

**C88: Water Entering
Page 24 of 24

Technical Service Bulletin: 2001-03 Elantra Corrosion in The Front Door Wiring Connector

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Technical Service Bulletin: 2001-03 Elantra Corrosion in The Front Door Wiring Connector

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Copyright:

Formatos disponibles

Technical Service Group

This bulletin supersedes TSB# 03-90-009 to update the sealant information.

KIT CONTENT: ID TAPE COLOR

3. Heat Shrink Tube

CONNECTOR KIT IDENTIFICATION:

CONNECTOR KIT IDENTIFICATION:

Pin #8 (MD03) - Gray - Brown

PARTS REQUIRED (CONTINUED):

3M Flexiclear Body Seam

Contact Cleaner Source Locally

Connector Grease 00305-F0000-39

SEALING THE PANEL SEAMS:

HOOD PANEL HOOD PANEL

RIGHT FENDER PANEL LEFT FENDER PANEL

3. Lift up the lower end of windshield glass

4. Clean the sealant application area on both “A” PILLAR

NOTE: Apply enough sealant to “A” PILLAR

- Photo shows panel seams where

10. Use appropriate tool or finger (with

- Sealant is applied along the top “A” PILLAR

- Sealant is applied along the bottom

DRIVER’S SIDE DOOR WIRING CONNECTOR INSPECTION:

3. Remove the front door checker mounting

- The bottom hinge bolts are similar.

4. Have a helper support the door. Use a

5. Release the 4 connector locking clips by

7. Remove the front door assembly. Set it on

9. If the connectors are not corroded or are CONNECTOR

Inject connector grease into each

Proceed with driver’s side door

11. Place the removed front door assembly

PASSENGER’S SIDE DOOR WIRING CONNECTOR INSPECTION:

4. Unclip the main wire harness from the

8. If connectors are not corroded or are just CONDUCTIVE

NOTE: If the connector terminals have

Proceed with passenger’s side

10. Fit the grommet over the flange on the SEALANT

11. Carefully install the door wire connector PASSENGER’S SIDE

connector, remove the connector,

15. Use a wire tie to secure the door BOLT

16. Install the right cowl side trim.

19. Close the hood.

2. Take the most corroded wire in the

• If the wires are corroded more than 2

4. Slide a piece of the heat shrink tube onto

5. Solder the wires.

7. Some wires on the new door connector kit

8. Wrap the spliced wire harnesses with the

9. Remove the front door quadrant inner

10. Remove the door trim mounting screws

11. Remove the door trim seal.

DOOR TRIM SEAL

12. Disconnect the door speaker connector

14. Replace the door wiring with a new

DOOR WIRING ASSEMBLY PART NUMBER INFORMATION:

PRODUCTION DATE RANGE PART DESCRIPTION PART NUMBER

15. Install the front door speaker.

20. Place the removed front door assembly

PASSENGER’S SIDE DOOR WIRING CONNECTOR AND DOOR WIRING

PRODUCTION DATE RANGE PART DESCRIPTION PART NUMBER

INNER FENDER PANEL SEAM SEALING:

3. Remove the plastic front wheel guard